Case Study: Casting Scrap Reduction

Design cores, molds and castings with excellence

 

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The Problem

Consistent core quality is a prerequisite for achieving controllable casting quality. Several casting problems, such as metal penetration or core gas-related defects, can be directly attributable to the quality of the cores used in production.  Uniform, predictable, controllable cores are desired.


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The Solution

Arena-flow is the foundry engineering software package used to model the filling and curing of sand cores and molds. Arena-flow's unique Computational Particle Fluid Dynamics (CPFD) numerical formulation models not only the granular sand motion and air flow in the tooling, but also the significant interaction between the two. Arena-flow calculates details of your tool's fill and miss-fill, plus localized density variations within a filled core. [Photo]

The Cost-Savings

One Arena-flow customer had an excessive scrap rate due to metal penetration defects in a shell mold used to produce cam shaft castings. The Arena-flow calculation predicted the existence and cause of an inconsistent mold density in this region. Simple tooling modifications were suggested which consistently improved the quality of both the mold and castings. The cost-savings were related to a reduction of both core and casting scrap.

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Your Foundry Application

Where is there room for improved quality in your casting process? Do you produce a casting that could benefit from improved quality? Is any inconsistency in quality related to cores or molds? Contact us to see if Arena-flow can help you design cores, molds and castings with excellence.

Case Studies

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    Core Scrap Reduction

    Cost savings are obtained by reducing the scrap rate for a cylinder block water jacket core.

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    Casting Scrap Reduction

    Cost savings are obtained by reducing the scrap rate for cam shaft castings produced by two shell mold halves.

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    Cycle Time Optimization

    Cost savings are obtained by reducing the cycle time for a precision sand cover core.

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    Capital Cost Savings

    Significant capital cost savings are obtained by optimizing each core in a core package.

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Still not convinced?  Give us your most challenging core and see what we can do.

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